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D3 Rebuild by No.6
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Number6
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January 22, 2020 - 12:16 am
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Greeting peeps! I am in the process of acquiring a 1955 D3, but which is pretending to look like a D1 (is green). That's OK because I want a D3 and I like the colour. smile I used to have a '55 D3 until about 25 years ago. In fact, it was my first motorbike and which I learned to ride on, way back in 1975. It was my dad's before; around 1963 or so, he bought it from someone next door to where he worked, for £5, just to get home on, as his car had been in an accident with a lorry and wasn't drivable. I think that was the only time he rode it because it had a lot of issues (apparently the seller's kids rode it around on the fields), so he started pulling it apart to fix it. But either he couldn't find a part or lost interest, so it sat in the spare room for 12 years. Then I left college for my first job, commuting by train was extortionate (even in those days!), so needed cheap transport. Well there's this bike cluttering up the spare room... I had no special interest or desire to get into motorbikes at the time (I had recently been trying to pass a car driving test), but it grew on me, such that consequently I have owned at least one motorcycle ever since. I now have a Russian Ural 750 CT sidecar outfit, which is an absolute hoot.

I should make it clear that the Bantam in the above story (my dad's) is NOT the same one that I have now, altho is same year and model. Apparently this one spent most of its life in and around Macclesfield, so I'm told (I grew up and lived in Essex). I have since retired to Lincolnshire; there's lots and lots of small country roads and lanes near me, ideal for a Bantam.

I have also been quite into audio electronics over the years; I used to work for Maplin Electronics, helping to produce their catalogues and magazines. From there that led me onto selling electrical transformers online, specifically for Hi-Fi valve amplifiers and guitar amps. I still make the odd valve amplifier, and belong to a group of like minded DIY valve audio enthusiasts. In fact there are a couple of projects I should be getting on with...

It's a plunger. Which reminds me, memory may be playing tricks again (often does) but are the top plunger springs so tough you can't compress them just by leaning on it? I'm not that heavy...

Photo taken today...

My-Bantam_2976.jpg

A number of things need looking at. The control cables are bone dry, so is the chain. Clutch cable routed very badly. Front gaiters shot (but I was given new ones with). Wiring harness is a mongrel; it's got a pattern Lucas 564 type rear lamp, with dual filament bulb, the brake filament works despite it being a direct AC lighting version (no battery), but also means, the electric horn doesn't, but I have a cunning plan to add a small SLA just so it can work. Rear brake rod is bent into a curve (presumably to avoid rubbing lower frame tube) and the brake switch fitting is a bit of a bodge. Front brake appears to be just for show, or finger/hand strengthening exercises. Rear tyre is rubbing on a mudguard stay nut. The bike has recently been rebuilt, and registered with DVLA 2017, but I suspect not actually used!

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Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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b175er
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January 22, 2020 - 4:22 pm
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It looks great. I'll just repeat what Wildun (Chris) said; come to meet us at Bardney. It's always a pleasant affair. Ken.

two B175s and a CB360

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Number6
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January 22, 2020 - 7:47 pm
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It looks great from a distance! laugh

What about my question about the rear springs?

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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January 22, 2020 - 9:30 pm
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Hi Mike!

We`ve got some dirty great potholes here in East Lincs you can try your rear springs out on! Obviously for safety`s sake starting off at 1mph. You didn`t say what weight/pressure you were exerting. I get my `54 D3 project out at the weekend, so can give it my 6ft 12st leverage if you wish? Haven`t you got a large neighbour...one of my local DJs is 6ft 1" 22st, he`s a helpful chap, I can message him for you.

In this exploded diagram...** Please log in to view **....you can picture how easily lack of lube can cause plunger tube to seize on plunger column, but surely the restorer added some grease when they refitted all the rear gubbins into the freshly stove enameled? frame. Maybe they were grease averse, one of those types that adds the grease later, but never did and it rusted-up being stood?

Very nice little bike once you`ve sorted the usual teething problems.

Blue

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wildun
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January 23, 2020 - 12:25 am
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Mike,

That looks good. Also, having a few issues with it helps you to find your way about the bike and get used to it. On my plunger I can quite easily bounce the springs down but only about 3/4 inch. Perhaps, as others say, if there is not much sign of grease on the bike and it has not been used then they may well be seized through standing. Another little job for you, maybe the first of several.

Keep us updated with progress.

1951 Bantam D1 125, 1954 Bantam Enduro 125, 1970 Bantam B175, all Bantams on the road and ridden regularly, 1995 Yamaha Diversion 900 and 2016 Honda Integra 750 scooter. Horses for courses, all very different to each other, but a bike for every occasion.

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Number6
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January 23, 2020 - 7:31 pm
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Thanks peeps.

We`ve got some dirty great potholes here in East Lincs you can try your rear springs out on! Obviously for safety`s sake starting off at 1mph.

Yes there's more than enough of that near me. (Boston.)

 

You didn`t say what weight/pressure you were exerting.

Just leaning on it while trying to prevent it falling over at the same time. It am do not want to play.

 

That looks good. Also, having a few issues with it helps you to find your way about the bike and get used to it. On my plunger I can quite easily bounce the springs down but only about 3/4 inch. Perhaps, as others say, if there is not much sign of grease on the bike and it has not been used then they may well be seized through standing. Another little job for you, maybe the first of several.

The "to do" list is rapidly growing. Deffo summat up with rear end, like you say, seems locked up. The whole thing is bone dry, no oil on the cables, chain, or anything else. I'm wondering if there's actually any oil in the gearbox, not looked yet. So no guarantee any grease has been added either. Anyway a brand new tin of grease arrived in the post today, so now I can refilll my grease gun, which hasn't seen daylight for years!

Tomorrow hopefully I'll look at getting it into the conservatory where there'll be more room to move around and much more light, and heating, and better access to the kitchen, and comfy chairs, etc. etc. I'll empty the tank tho.

I just want to make sure it's safe to use so need to check out everything in that regard. Also I want to rewire it so am looking at that.

Onwards!

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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January 23, 2020 - 9:05 pm
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Number6 said

 

Tomorrow hopefully I'll look at getting it into the conservatory where there'll be more room to move around and much more light, and heating, and better access to the kitchen, and comfy chairs, etc. etc....

I discovered in my w/shop that the rear carrier/rack makes an excellent in situ cake tray stand, complete with pot of tea.

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Number6
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January 23, 2020 - 9:14 pm
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Good idea! Looking more attractive by the minute laugh

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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Number6
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January 24, 2020 - 9:03 pm
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Grips looked OK from above, but twist them around the bar and, from underneath...

Bantam_2982.jpg

Bantam_2983.jpg

Good news, the wheels and steering head bearings seem good, no play or roughness.

Bad news, both chains are toast. Clutch plates look toast too.

Final drive chain adjusters are wound up to the limit, and then washers added under the nuts to get more! This explains why the rear tyre rubs on one of the rear mudguard's back stay nut. Meanwhile, at t'other end, primary chain is starting to gnaw away at its cover.

I was right to guess the lack of gearbox oil, nothing on dipstick, shoved a long thin screwdriver right down to the bottom and got about 1/8 inch. Drained it anyway, got about a small teacup's worth?

Bantam_2986.jpg

Oil grey and manky, but no metal bits. Bizarrely I couldn't find a spanner size to fit the drain (and filler) plug, but 18mm is a dead fit?? Just so happened I got a socket 'specially, to add to my set, as 18mm is an odd size insofar that you don't get it in socket and spanner sets normally.

More good news, clean healthy drain plug threads! Hex corners a mite chewed tho. I hate it when people welly up drain plugs like they're terrified they're going to unscrew themselves and fall out. (?)

Nothing too scary about any of this, so far, it's just gagging for a good service.

More good news, Ural toolkit C spanner can work on Bantam exhaust nut too!

Bantam_2987.jpg

Silencer is new and shiny but pipe and nut are very rough, so having new ones.

Shortly after disposing of the old oil, bad light stopped play.

Today's shopping list...

Bantam_2988-1.jpg

From previous shopping lists...

Bantam_2981-1.jpg

Laters.....

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Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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chickensoup
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January 24, 2020 - 9:16 pm
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Hi Mike,

Great to see you are cracking on with your repairs. Nice to see updates with photo's. Keep up the good work and you will be on the road for when the better weather arrives..

Nick

1950 BSA D1 Plunger   242 UYW

1966 BSA D7  LBF 62 D

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Blue Heeler
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January 24, 2020 - 9:37 pm
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Cozy!

Clutch cover primary chain nibbles are very common. Not really necessary once a new chain fitted, but some folk buy or fabricate a chain tensioner...used more as a guide to take up the slack, of which there`ll still be some even with a new chain.

Mainly the trials chaps that fit them, necessitated by their fitting a different crank sprocket, but some folk with standard road-going Bantams on here have them. Probably quieten things down a touch?

Blue

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wildun
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January 24, 2020 - 10:05 pm
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Hey Mike, great to see that you are cracking on with the work.

Your parts list,

handlebar rubbers,your choice of style.

Dip switch, may I suggest that you look at a Ducon switch with horn button. These should not blow your rear light when you use the dip switch.

Rear chain. As you are going to ride your bike, please be aware that the correct chain for the Bantam is a 1/2 X 3/16 X .335, either Renold or Regina are the popular choice. The 420 chains offered by some suppliers are not suitable for use with original sprockets, they will fit but the rollers are not the correct diameter and will prematurely wear your sprockets.

Primary case screws. I think that it may be easiest to buy a complete engine set. Different Bantam models had different threads. Make sure that you order the for the correct engine.

That drain plug, and filler and other bolts if original will be Whitworth spanner sizes. You only need a few sizes, pick them up at autojumbles or boot sales. As you have found out, other sizes may fit in some instances.

Primary chains are generally available. Get a good quality make. Renold, Iwis etc with a split link and it will last a long time. I personally have never fitted a tensioner to any of my engines.

Clutch plates again, are generally available. Your choice. You will need a clutch compressor tool, quality varies, bit of a knack using them.

But, you are going well, spend a bit of money and time now then, once you are happy everything is sorted, leave it alone and ride it !

1951 Bantam D1 125, 1954 Bantam Enduro 125, 1970 Bantam B175, all Bantams on the road and ridden regularly, 1995 Yamaha Diversion 900 and 2016 Honda Integra 750 scooter. Horses for courses, all very different to each other, but a bike for every occasion.

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Number6
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January 24, 2020 - 10:33 pm
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Dip switch, may I suggest that you look at a Ducon switch with horn button. These should not blow your rear light when you use the dip switch.

Thanks, took me a few minutes to fall in what that means, but yeah I see what you mean.

 

Rear chain. As you are going to ride your bike, please be aware that the correct chain for the Bantam is a 1/2 X 3/16 X .335, either Renold or Regina are the popular choice. The 420 chains offered by some suppliers are not suitable for use with original sprockets, they will fit but the rollers are not the correct diameter and will prematurely wear your sprockets.

Thanks so I read here! Spent HOURS this afternoon and evening looking, but eventually found some firm sells Regina of the right sizes, specifically for Bantam they say, we shall see.

 

Primary case screws. I think that it may be easiest to buy a complete engine set. Different Bantam models had different threads. Make sure that you order the for the correct engine.

On order. Original head slots really knackered, so was impact driver time. They're not going back!

 

That drain plug, and filler and other bolts if original will be Whitworth spanner sizes. You only need a few sizes, pick them up at autojumbles or boot sales. As you have found out, other sizes may fit in some instances.

That explains that! Thanks. laugh

 

But, you are going well, spend a bit of money and time now then, once you are happy everything is sorted, leave it alone and ride it !

Yep, trying to get to that stage. Thanks

 

I should probably continue on a new topic .. laugh

 

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Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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wildun
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January 24, 2020 - 10:38 pm
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Cocorico,

Agreed, perhaps it is time to suggest that Mike posts in a different section, but which one ? He is telling his story as an enthusiastic new owner rather than asking specific questions. Don't let us discourage him.

I will let you advise him which section is most appropriate. 

Regards.

1951 Bantam D1 125, 1954 Bantam Enduro 125, 1970 Bantam B175, all Bantams on the road and ridden regularly, 1995 Yamaha Diversion 900 and 2016 Honda Integra 750 scooter. Horses for courses, all very different to each other, but a bike for every occasion.

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Number6
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January 24, 2020 - 10:45 pm
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Blue Heeler said
Cozy!

Clutch cover primary chain nibbles are very common. Not really necessary once a new chain fitted, but some folk buy or fabricate a chain tensioner...used more as a guide to take up the slack, of which there`ll still be some even with a new chain.
  

Yes I remember this from my other, first, D3 years ago. Never needed a "guide", but did need and get a new chain, and of course there's a bit of slack. Better than tight.

But thing I like best about a Bantam's primary chain is the spring link! So changing is a doddle, compared to pulling sprockets off as a set. (I used to have Moto Guzzis, on those it means pulling off 3 sprockets at once. Understandably, chain renewal was frequently neglected as people just didn't want to do it.)

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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January 24, 2020 - 10:45 pm
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I suppose D1 D3 D5 D7 Restorations Documented, I suppose is more suitable for ongoing restoration story.

1951 Bantam D1 125, 1954 Bantam Enduro 125, 1970 Bantam B175, all Bantams on the road and ridden regularly, 1995 Yamaha Diversion 900 and 2016 Honda Integra 750 scooter. Horses for courses, all very different to each other, but a bike for every occasion.

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Number6
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January 28, 2020 - 8:50 pm
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.... aaaa-and we're back! In a new section. Ta muchly to the mods for the move. smile

 

Progress been slow due to other stuff getting in the way, also, me getting hung up on unexpected discoveries then going off on an OCD fuelled Internet browsing session to see what else I might need to buy or form a "plan" what to do next. It's all very fluid at the mo.

But, the speedometer works! We like that don't we?

Tho I had to extricate the cable from where it was trapped between gearbox and frame, and thus doing an acute S-bend. I read here should go under the frame at that point, where the footrest rod goes through, and that works a treat.

Few more pix...

Tank off, and wiring is pronounced junk...

Bantam_2989.jpg

Thick bit under tube looks like original "harness", wrapped in old cloth insulation tape. Black thing viisible just above and behind top tube is actually the throttle cable, held in place by yet two more of these horrible rubber "zip-ties" I keep finding.

 

Seat is rusty scrap.

Bantam_2990.jpg

It's a Wassel. A decent cover from another one has been put over its frame so it looks OK from the above. Not even clipped down properly.

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Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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Number6
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January 28, 2020 - 8:57 pm
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OMG. 1980's R-series boxer BMW toolkit tyre hand pump fits Bantam tank lugs. How cool is that.

Bantam_2992.jpg

 

Today – another view of the wiring. Note masking tape at bottom of picture, at mudguard grommet.

Bantam_2993.jpg

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Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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Number6
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January 28, 2020 - 9:13 pm
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Anyway, it's all coming off. That means going into the headlight bucket...

 

Headlamp bulb connector...

Bantam_2996.jpg

 

Bantam_2997.jpg

 

Bulb is lovely, looks like a new one, but headlamp itself is scrap. Something else to add to the list.

The rear light, I have now correctly identified as a Lucas L525 pattern. Headlight bulb is P36D 6V 30/24W. Tail light is BAY15D 12V, can we guess why? laugh

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Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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Number6
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January 28, 2020 - 9:18 pm
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Rest of the afternoon was spent getting rear mudguard off. Something weird going on with it. The rear stays were massively under tension; once off, they seem about 10mm too short. (?)

Bad light stopped play...

Mike H --

Murphy's 4th law of motion states that any small object that is accidentally dropped will immediately hide itself under a larger object.

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